Lightweight nonwoven fabric having improved performance

Abstract

The present invention relates generally to nonwoven materials, and specifically, to a nonwoven fabric comprised of at least two continuous filament precursor webs, each precursor web being of a polyolefin polymer dissimilar from that of the other precursor web, wherein the resulting lightweight nonwoven laminate fabric exhibits improved tactile and ductile qualities, the nonwoven fabric being imminently suitable for application in improving the comfort and use of hygiene, medical and industrial products. The lightweight nonwoven fabric is manufactured with a minimum level of processes complexity, and can be either used as a replacement for an existing facing layer, such as a topsheet of a hygiene product, or used in conjunction with an existing construct so as to improve long-term comfort.

1. A method for forming a nonwoven laminate fabric, comprising the steps of:
 a. providing a first polyolefin polymer, 
 b. providing a second polyolefin polymer, wherein said second polyolefin polymer is dissimilar to said first polyolefin polymer, 
 c. forming said first polyolefin polymer into a first continuous filament precursor web having a basis weight of no more than about 12 grams per square meter, 
 d. forming said second polyolefin polymer into a second continuous filament precursor web having a basis weight of no more than about 12 grams per square meter, wherein said second continuous filament precursor web is formed on the surface of said first continuous filament precursor web, and 
 e. consolidating said first and said second continuous filament precursor web by application of elevated temperature and pressure to form a nonwoven laminate fabric; 
 including providing a thermoplastic polymer, in the form of meltblown fibers, exhibiting a melt temperature profile that is compatible with the thermoplastic composition of the first and second polyolefin polymers, and 
 applying said thermoplastic polymer onto said first continuous filament precursor web at a component basis weight level of no more than about 3 grams per square meter to form a thermoplastic adhesion layer. 
 
     
     
       2. A method for forming a nonwoven laminate fabric, comprising the steps of;
 a. providing a first polyolefin polymer, 
 b. providing a second polyolefin polymer, wherein said second polyolefin polymer is dissimilar to said first polyolefin polymer, 
 c. forming said first polyolefin polymer into a first continuous filament precursor web having a basis weight of no more than about 12 grams per square meter; 
 d. forming said second polyolefin polymer into a second continuous filament precursor web having a basis weight of no more than about 12 grams per square meter, 
 e. juxtaposing said first continuous filament precursor web and said second continuous filament precursor web in face to face relationship, and 
 f. consolidating said first and said second continuous filament precursor web by application of elevated temperature and pressure to form a nonwoven laminate fabric; 
 including providing a thermoplastic polymer, in the form of meltblown fibers, exhibiting a melt temperature profile that is compatible with the thermoplastic composition of the first and second polyolefin polymers, and 
 applying said thermoplastic polymer onto said first continuous filament precursor web at a component basis weight level of no more than about 3 grams per square meter to form a thermoplastic adhesion layer. 
 said juxtaposing step including juxtaposing said combined first continuous filament precursor web and thermoplastic adhesion layer with said second continuous filament precursor web in face to face relationship.